Ford Technical Service Bulletins

ProblemModelBulletinOil leaking from the rear of the right cylinder head or the front of the left cylinder head1998-2003 Expedition, Excursion and E/F Series Trucks with 4.6L or 5.4L two-valve engine02-22-7spark knock or harsh engagement when the transmission is shifted into ‘Drive’999-2000 Windstar; 2000-01 Taurus with 3.0L 2V/FFV engine02-24-3An illuminated 4X4 lamp, inoperative or inaccurate speedometer, and/or code P1635 or P16391999-2002 Mustang, Expedition, F-150; 2000-02 Focus, E-Series; 2001-02 Explorer, Ranger02-23-4Erratic or failed interior temperature control1996-2003 Taurus/Sable; 1998-2002 Continental02-23-6MIL illumination with DTC P0401, P0402, P1400 or P14012000-02 Taurus/Sable; 2001-02 Crown Victoria, Focus, Mustang, E-Series, Escape, Expedition, Explorer, F-150, Ranger, Windstar, Town Car, Cougar, Grand Marquis, Mountaineer03-2-2Ford has developed a new oil pan gasket and installation kit for the 3.0L V6 engine.1986-2001 Taurus, Probe, Tempo, Aerostar, Ranger, Windstar, Mercury Sable, Topaz with 3.0L 2V Vulcan engine05-5-3An MIL illumination with DTC P0171 or P0174 indicates a lean mixture condition1999-2000 Windstar03-3-8Air Bag Warning light illumination and DTC B2290 indicate a problem with the Occupant Classification Sensor (OCS).2001-03 Windstar03-5-41998-2003 Expedition, Excursion and E/F Series Trucks with 4.6L or 5.4L two-valve engine Oil leaking from the rear of the right cylinder head or the front of the left cylinder head may be caused by the manufacturing process. During assembly, metal chips may have lodged between the castings and the head gasket near the high pressure oil passage. A new “Service Only” head gasket is available that seals in a different ‘foot print’ around that oil passage. The bulletin lists part numbers by application and a list of the effected engines. Bulletin 02-22-71999-2000 Windstar; 2000-01 Taurus with 3.0L 2V/FFV engine On vehicles with the flex fuel engine, spark knock or harsh engagement when the transmission is shifted into ‘Drive’ may be caused by PCM calibration. If no other reason for a lean condition can be found, a new calibration is available, but the Fuel Octane program must also be adjusted after recalibration. The bulletin includes a long list of calibration numbers and instructions for using the NGS Tester. Bulletin 02-24-3back1999-2002 Mustang, Expedition, F-150; 2000-02 Focus, E-Series; 2001-02 Explorer, Ranger An illuminated 4X4 lamp, inoperative or inaccurate speedometer, and/or code P1635 or P1639 after replacing the PCM or instrument panel is caused by PCM programming procedures. The Vehicle Identification (VID) block must be entered into the PCM during calibration. The VID is contained in the original PCM and can be retrieved using the NGS tester. If the PCM will not communicate or is not available, the VID is available only through Ford’s Professional Technician Society dealer-tech-only Web site. Otherwise the NGS tester can be used to transfer the VID from one PCM to another or to complete the instrument panel reprogramming. The bulletin has complete instructions. Bulletin 02-23-41996-2003 Taurus/Sable; 1998-2002 Continental Erratic or failed interior temperature control may be caused by a bound or distorted Secondary Blend Door. ETAC codes B1249, 022, 024 or 025 also may be present. A replacement blend door is now available and can be installed without replacing the entire heater case, but the instrument panel must still be removed from the vehicle. The bulletin includes part numbers and instructions for installing the door. Bulletin 02-23-62000-02 Taurus/Sable; 2001-02 Crown Victoria, Focus, Mustang, E-Series, Escape, Expedition, Explorer, F-150, Ranger,Windstar, Town Car, Cougar, Grand Marquis, Mountaineer
MIL illumination with DTC P0401, P0402, P1400 or P1401 and/or rough running, low power, surge and poor fuel economy all indicate problems with the DPFE sensor on the EGR system. If the vehicle has a tube-mounted DPFE sensor and one of these codes are present, the bulletin instructs to install a new sensor, P/N 2F1Z-9J460-AA. Bulletin 03-2-2back1986-2001 Taurus, Probe, Tempo, Aerostar, Ranger, Windstar, Mercury Sable, Topaz with 3.0L 2V Vulcan engine Ford has developed a new oil pan gasket and installation kit for the 3.0L V6 engine. The new molded gasket attaches to the pan, not the block, and the kit (2U7Z-6710-AA) includes new longer oil pan bolts that must be torqued in two steps. The bulletin includes illustrations and complete installation instructions. Bulletin 03-5-31999-2000 Windstar
An MIL illumination with DTC P0171 or P0174 indicates a lean mixture condition, which may be caused by a loose fitting on the fuel pressure regulator vacuum line and/or a vacuum leak between the upper and lower intake manifold. The repair may include reprogramming the PCM. The bulletin includes diagnostic procedures and PCM calibration numbers. Bulletin 03-3-82001-03 Windstar
Air Bag Warning light illumination and DTC B2290 indicate a problem with the Occupant Classification Sensor (OCS). This sensor determines the size of the right front seat occupant for adjusting air bag deployment force. The problem may be caused by a loose wiring connector under the passenger seat, loss of power or ground at the green connector, or a non-functioning OCS or air bag control module. The bulletin includes diagnostic and repair procedures, part numbers and illustrations showing component locations. Bulletin 03-5-4